SIL classification study for Bharatpur Terminal of IOCL

IOCL Bharatpur Terminal (a public sector organization) was commissioned in 1993 & is having facility for receipt, storage and dispatch of petroleum products viz Motor spirit (MS), High Speed Diesel (HSD) and Ethanol. Till 2010, the mode of receipt of product at Bharatpur Terminal was primarily through rakes i.e. rail transportation. After the year 2010, product pipeline from Mathura Refinery to Bharatpur Terminal was commissioned along with the setting up of Pipeline Station under the premises of Bharatpur Terminal. The main activities of the IOCL, Bharatpur Terminal are Receipt, Storage and Delivery. The Terminal receives, stores and distributes Petroleum Products like Ethanol Blended Motor Spirit (EBMS) and High Speed Diesel (HSD). The Terminal also handles Ethanol, which is mixed in a proportion of 12% by volume with MS for dispatch. The process involves receipt of products through pipeline and tank wagons and storage in above ground/ underground tanks. At the Terminal Blending of high‐performance Petrol and Diesel is done which is followed by dispatch/filling of different products in Tank Trucks and distribution to retail outlets and various consumers across the districts of Rajasthan.

All products except Ethanol is received by Pipeline in addition to that Railway Gantry and Tank Truck decantation facilities are also available for receiving the product. Ethanol is received through Tank Trucks only.

Distribution and other related activities carried out at the terminal can be grouped into two parts

  1. Pipeline Receipt/ Tank Wagon /Tank Truck decantation and receipt in storage tanks
  2. Filling and distribution through Tank trucks

MS is stored in Internal Floating Roof Tank (FRT) and HSD is stored in Cone Roof Tanks (CRT). 04 nos. of underground tanks provided for the storage of Ethanol and MS. All the tanks are provided with CC / brick pitching to the apron and foundations. All the storage tanks are provided with 2 Nos. of valves one is ROSOV and second is DBBV for safety reasons. Fire protection system is adequately provided for all tanks.

As per the scope of this SIL Classification study, safety instrumented functions (SIFs) were identified in the P&IDs and the C&E matrices, relevant to the project, having the following objectives

  1. Identify potential risks inflicted on people, environment, and assets due to the failure of safety-related systems and associated facilities in the plant to operate on demand.
  2. Define the basic performance requirements of all Safety Related Instrumented systems to reduce the above risks to “As Low as Reasonably Practicable”.

Layers of Protection Analysis (LOPA) has been used in this study. It is an effective analytical method for determining whether the layers of protection utilized to reduce process risk are enough. LOPA builds upon well‐known process hazards analysis techniques, applying semi‐quantitative measures to the evaluation of the frequency of potential incidents and the probability of failure of the protection layers. It is a simple tool that identifies the safeguards to be considered for risk classification and risk reduction.